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Procedia Structural
Structural IntegrityIntegrity
Procedia500
(2017) 123–130
(2016) 000–000
www.elsevier.com/locate/procedia

2nd International Conference on Structural Integrity, ICSI 2017, 4-7 September 2017, Funchal,
Madeira, Portugal

Failure Analysis
XV Portuguese of Composite
Conference Repaired
on Fracture, PCF 2016, 10-12Pipelines with
February 2016, Paçoan
de Inclined
Arcos, Portugal
Crack under Static Internal Pressure
Thermo-mechanical modeling of a high pressure turbine blade of an
Amr A. Abd-Elhadya,b,*,airplane gas turbine
Hossam El-Din M. Sallamengine
a,c
, Muhammad A. Mubarakia
aFaculty of Engineering, Jazan University, Jazan 706, Kingdom of Saudi Arabia.
a
a b c
bOn
P. Brandão , V. Infante , A.M. Deus *
On sabbatical leave from Faculty of Engineering, Helwan University, Cairo, Egypt.
b
cc
On sabbatical leave from Faculty of Eng., Zagazig University, Zagazig, Egypt.
a
Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Portugal
b
IDMEC, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Portugal
Abstract
c
CeFEMA, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Portugal
The aim of the present work is to study the efficiency of the glass fiber reinforced polymer patch for repairing cracked steel pipe
subjected to internal pressure. The effect of fiber orientation, [0oo]8s 8s, [90 ]8s
oo , and [0oo/90oo] , of bonded composite repair on reducing
8s 4s
4s
J-integral
Abstractof stationary crack with different inclination angles () is studied using the 3-D finite element method, FEM. Extended-
FEM has been adopted to simulate the crack growth of different inclined stationary cracks in steel pipe subjected to internal
pressure.
During Ittheir
has been found that,
operation, the growing
modern aircraft crack
engine emanated from inclined
components stationary
are subjected crack switched
to increasingly its path to be
demanding under pure
operating mode
conditions,
especially
I. The crack the high pressure
initiation pressureturbine (HPT)
of inclined blades. Such
stationary crackconditions
in steel pipecausewith these parts torepair
composite undergo different
is higher types
than thatof
oftime-dependent
pipe without
degradation,
composite oneThe
repair. of which is creep.
composite repairAreduced
model using the finite
the value element of
of J-integral method (FEM)
stationary wasindeveloped,
crack steel pipe.in order
This to be able
reduction to predict
is strongly
the creep
affected behaviour
by the of HPT
crack length and blades. Flight data
of the stationary records
crack and it(FDR)
is fairlyfor a specific
affected by theaircraft, provided by a commercial aviation
fiber orientation.
© company, were used
2017 The Authors. to obtainbythermal
Published ElsevierandB.V. mechanical data for three different flight cycles. In order to create the 3D model
© needed
2017 Thefor
Authors.
the FEMPublished by Elsevier
analysis, a the
HPT B.V.blade scrap was scanned, and its chemical composition and material properties were
Peer-review
Peer-review under responsibility of Scientific Committee ICSIof2017
ICSI 2017.
obtained.under responsibility
The data that wasofgathered
the Scientific
was Committee
fed into theofFEM model and different simulations were run, first with a simplified 3D
rectangular
Keywords: Mode block shape,
of mixity; in order
stress to better
intensity factors;establish the
J-integral; model, and
composite then
repair with
patch; 3-Dthe
FEMreal 3D mesh obtained from the blade scrap. The
overall expected behaviour in terms of displacement was observed, in particular at the trailing edge of the blade. Therefore such a
model can be useful in the goal of predicting turbine blade life, given a set of FDR data.
1. ©Introduction
2016 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the Scientific Committee of PCF 2016.
Steel pipelines are increasingly used for a variety of applications, such as in the oil, gas and high pressure container
Keywords: Operating
industries. High Pressuresteel pipe
Turbine in cruel
Blade; Creep;environmental conditions
Finite Element Method; can Simulation.
3D Model; expose it to a variety of damage types such as
erosion, corrosion, and mechanical damage (El-Bagory et al., 2013, 2014, and 2015).

* Corresponding author. Tel.: +966-564-612-865 ; fax: +966-173-232-600.

E-mail address: aelhady@jazanu.edu.sa , aaa_elhady@yahoo.com

2452-3216 © 2017 The Authors. Published by Elsevier B.V.

Peer-review underauthor.
* Corresponding responsibility
Tel.: +351of218419991.
the Scientific Committee of ICSI 2017.
E-mail address: amd@tecnico.ulisboa.pt

2452-3216 © 2016 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the Scientific Committee of PCF 2016.
2452-3216  2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the Scientific Committee of ICSI 2017
10.1016/j.prostr.2017.07.077
124 Amr A. Abd-Elhady et al. / Procedia Structural Integrity 5 (2017) 123–130
2 Amr A. Abd-Elhady et al. / Structural Integrity Procedia 00 (2017) 000–000

Damage is the main cause of crack initiation, and so bonded composite repair can be used to prevent leakage and
restore all or part of the maximum allowable operating capacity of the pipeline. Furthermore, fiber reinforced polymer
(FRP) materials are highly suited for use as repair material, as they possess a very high specific strength and stiffness,
a high formability, an inherent immunity to corrosion, and ease of fabrication (Baker 1999). A number of studies have
investigated pipeline with bonded composite patches, notably Shouman and Taheri (2009), Alexander and Ochoa
(2010), API (2000), ASME (2006) and Köpple (2013).

Failure analysis of pipe made of glass-reinforced plastic with an inclined surface crack under static internal pressure
was investigated by Arikan (2010). He concluded that, the crack propagation occurred in Mode II. He mentioned that,
the critical stress intensity factor according to mixed mode must be determined in order to study the failure of pipe
with crack. Alexander and Ochoa (2010) developed a composite repair system of steel pipeline, formed from
unidirectional fibers wrapped in the circumferential direction of the pipe. Moreover, Alexander and Ochoa (2010)
deduced a formula to calculate the sufficient thickness of the repair wrap, depending on the ultimate tensile strength
of the steel pipe and the ultimate tensile strength of the repair wrap. Alexander and Ochoa (2010) also developed an
integrated analytical and experimental method to evaluate the integrity of an onshore composite repair technique.
They used a carbon/epoxy- based composite system as a repair for steel pipe. Shouman and Taheri (2009) studied the
response of repaired pipelines under internal pressure, axial force, and bending. Shouman and Taheri (2011) also used
glass-reinforced polymer to repair steel pipelines based on strain-based design. They found good agreement between
their experimental and numerical results. Shouman and Taheri (2011) concluded that the optimized design of
composite repaired steel pipelines depends on the fiber orientation of composite repair. The prediction of fracture
parameters such as J-integral, stress intensity factors (SIF), and failure strength is one of the most important aspects
in the design of composite repair.

If steel pipe is exposed to partial damage, the application of composite repair can reduce the spread of this damage.
In the present work, the partial damage can be considered as an inclined stationary crack. The present work attempts
to predict the path of crack emanating from inclined stationary crack located at the pipeline by the extended Finite
Element method X-FEM. Furthermore, the effect of bonded composite repair at the cracked pipeline on the emanating
crack path is examined. J-integral values of inclined stationary crack in steel pipe with/without composite repair have
been calculated numerically. The effect of the fiber orientation of composite repair on the evolution of the J-integral
of inclined stationary crack in steel pipe is examined.

2. Finite element method

2.1 Geometry and mechanical properties

The three-dimensional finite element model for composite repaired steel pipe consists of the pipe and glass fiber
reinforced polymer GFRP composite repair. The geometry of composite repaired steel pipe was selected based on
Shouman and Taheri (2011) and shown in Table 1. The typical repaired pipe model in the present work is shown in
Fig. 1.

Table 1. GFRP composite repaired steel pipelines geometry, Shouman and Taheri (2011)

Symbol Value Description

L 3000 Steel pipe line length (mm)
D 508 Steel pipe line length outer diameter (mm)
Di 496 Steel pipe line length inner diameter (mm)
a 5, 35, 75 and 110 Inclined crack length (mm)
Dr 540 GFRP composite repair diameter (mm)
 0o, 15o, 30o, 45o, 60o, 75o and 90o Inclined crack angle
 Amr A.
AmrAbd-Elhady et al /etStructural
A. Abd-Elhady Integrity
al. / Procedia Procedia
Structural 00 (2017)
Integrity 000–000
5 (2017) 123–130 1253

(a) (b) 

D
Dr

Fig.1. (a) A schematic repaired pipe used in the present investigation. (b) Stationary inclined crack

The unidirectional stiffness properties of the GFRP lamina composite repair material which was used in this
investigation are tabulated in Table 2 extracted from Shouman and Taheri (2011). The steel plate modeled as isotropic
material and elastic-plastic behavior is considered in the present analysis. The mechanical properties of the present
steel plate are given in Table 2. Eight angle plies in Uniaxial laminates [0o]8s (perpendicular to pipe axis), perpendicular
laminates [90o]8s (parallel to pipe axis) and cross ply laminates [0o/90o]4s are simulated with solid elements, and the
material properties of GFRP are defined as an engineering constant with using the mechanical properties included in
Table 2.

Table 2. Material properties and strength data, Shouman and Taheri (2011)
Symbol Value Property
Glass epoxy composite repair wrap material’s properties
E11 55 Young's modulus in fiber direction (GPa)
E22 15.2 Young's modulus in the transverse direction (GPa) (In Y direction)
E33 15.2 Young's modulus in the transverse direction (GPa) (In Z direction)
G12 4.7 In- plane shear modulus (GPa) (X-Y plan)
G13 4.7 In- plane shear modulus (GPa) (X-Z plan)
G23 3.28 In- plane shear modulus (GPa) (Y-Z plan)
12 0.254 Poisson's Ratio (X-Y plan)
13 0.254 Poisson's Ratio (X-Z plan)
23 0.428 Poisson's Ratio (Y-Z plan)
Steel pipe material’s properties
E 205 Young’s modulus (GPa)
 0.3 Poisson’s ratio
ym 413 Minimum yield stress (MPa)
y 0.5% Yield strain

2.2 Contact and loading regime

Pressure was loaded inside the pipe surface, P, at 100 MPa. In the present model, penalty friction formulation is
used to simulate the contact properties of crack surface. Coefficient of friction of 0.4 for steel-steel is used to simulate
the crack surface property (from Abd-Elhady and Sallam 2015). Master–slave contact interactions "surface to surface"
were applied between the outer surface of pipe and inner surface of composite repair as a tie contact.

2.3 X-FEM and fracture parameters (J-integral and stress intensity factor) Calculation

A 3-D elastic FE model has been developed using the ABAQUS program (ABAQUS 2002) to account for the
geometric and material behavior of composite repaired steel pipe. X-FEM has been used to simulate the fracture crack
path (Elguedj et al. 2006) in various crack analysis problems with different stationary inclined crack angles in pipe.
The X-FEM method enables simulation of crack propagation without reformulation of the finite elements mesh. In the
present work, the domain integral method is used to extract J-integral and stress intensity factors (SIFs) for steel plate
joint (Gosz and Moran 2002). The stress intensity factors KI, KII and KIII (mode I, mode II, and mode III SIF) are
usually used in linear elastic fracture mechanics to characterize the local crack-tip/crack-line stress and displacement
fields. They are related to the energy release rate (the J-integral) through:
126 Amr A. Abd-Elhady et al. / Procedia Structural Integrity 5 (2017) 123–130
4 Amr A. Abd-Elhady et al. / Structural Integrity Procedia 00 (2017) 000–000

1 1
𝐽𝐽 = (𝐾𝐾𝐼𝐼2 + 𝐾𝐾𝐼𝐼𝐼𝐼2 ) + 2
𝐾𝐾𝐼𝐼𝐼𝐼𝐼𝐼 (1)
𝐸𝐸̅ 2𝐺𝐺

̅ = E is modulus of elasticity and G = modulus of rigidity. The energy release rate is calculated directly in
Where E
ABAQUS/Standard.

2.4 Mesh

The mesh refinement process was carried out to assure that results are not dependent upon the elements size. A
typical mesh of a composite repaired steel pipe model is shown in Fig. 2. Each component (i.e., the pipe and repair) is
meshed by using eight-node linear brick, reduced integration elements (C3D8 in ABAQUS) because these elements
are compatible with the XFEM domain integral method.

Fig. 2. Finite element model.

2.5 Methodology of the present work

The present work is sequenced as:

 Determine the critical thickness of composite repair
 Determine the fracture parameters such as: J-integral and mode I, II SIF of stationary incline crack in steel
pipe
 Determine the crack path emanating from inclined stationary crack in steel pipe with different inclined crack
angle with/without composite repair
 Illustrate the effects of composite repair in steel pipe on the value of J-integral of inclined stationary crack
in steel pipe with different inclination angle and different fiber orientation of composite repair

3. Result and discussion

3.1 Preliminary study

In this section, the sufficient thickness of composite repair for reducing the harmful effects of the damage to steel
pipe has been checked. ASME has incorporated composite repairs for damaged pipes, by recently developing the
ASME Post Construction Repair Standard- PCC2 (ASME 2006). This standard has set a critical FRP repair thickness
to be applied to damaged pipelines, which can be computed by the following equation:

1 𝑃𝑃𝑃𝑃
𝑡𝑡𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = ∗( − (𝜎𝜎𝑦𝑦𝑦𝑦 )𝑡𝑡𝑠𝑠 ) (2)
𝐸𝐸𝐶𝐶 𝜀𝜀𝐶𝐶 2

where: Ec and c are the tensile modulus and allowable hoop strain of the composite in the hoop direction
respectively, and ts is the minimum remaining wall thickness in the pipe. The present thickness of composite repair
equals 16 mm, which is greater than tcrepair.
 Amr A. Abd-Elhady et al. / Procedia Structural Integrity 5 (2017) 123–130 127
Amr A. Abd-Elhady et al / Structural Integrity Procedia 00 (2017) 000–000 5

3.2 Mode I and mode SIF results

Figs. 3a and 3b show the effect of crack inclination angle, , of stationary crack, in steel pipe under internal pressure,
on the values of KI and KII versus the crack length, a. Fig. 3 shows that, the values of KI and KII are approximately
equal to zero for  = 0o. This means that, there is no possibility of finding a circumferential crack in such a case of
loading. The stationary crack with  = 90o (parallel to the pipe axis) is initiated under pure mode I, i.e., KII = 0.
Furthermore, the stationary crack with other values of  initiated as kinked under mixed mode condition to adjust its
direction to become parallel to the pipe axis. The stationary crack with  = 90o has highest values regardless of the
crack length, followed by the stationary crack with  = 75o. For  ranged between 30o and 60o, the order of KI depends
not only on  but also on the crack length. On the other hand, the highest values of KII ranged between  =30o and 
= 45o, depending on the crack length.

70 50
(a) Effect of incline crack angle on Mode I SIF (a) Effect of incline crack angle on Mode II SIF
60
40

Normalized Mode II SIF, YII

Normalized Mode I SIF, YI

50  
0 30 0
40 15 15
30
30
30 45 20
45
60
75 60
20
90 10 75
10 90

0
0

-10 -10
0 20 40 60 80 100 120 0 20 40 60 80 100 120
Crack Length, a (mm) Crack Length, a (mm)

Fig. 3. Mode I and Mode II SIF of inclined crack in steel pipe under internal pressure.

3.3 Stress Analysis

If the steel pipe has been exposed to partial damage, the composite repair can be reduce or arrest the spread of this
damage. Fig. 4 depicts the values of hoop stress in composite repair batch versus the distance from the tip of the
longitudinal crack ( = 90o) with different fiber orientations. Generally, the plies with 0o fiber direction (in the
circumferential direction) suffered from tensile stress due to the fiber direction being parallel to the tensile hoop stress
in the steel pipe and perpendicular to the stationary crack, while compressive stress was established in the plies with
90o fiber direction (in the longitudinal direction). The stress at the crack tip has the peak value and then decreases
gradually with increasing the distance from the crack tip. The hoop stress increases with increase in the crack length.
Furthermore, ply close (ply-1) to the cracked steel pipe has the highest stress.

700 -200 400

(a) a = 35 mm and 75 mm (b) a = 35 mm & [90]8s (c)a = 35 mm & [0/90]4s
-180
600 300
[0]8s -160
Hoop Stress, MPa

500 -140 200

Hoop Stress, MPa

Hoop Stress, MPa

-120
400 100
-100
0
300 a, mm -80
0 50 100 150
35- ply-1
-60 -100
200 35 - Ply-2
35 - Ply-3 -40
100 -200
35 - Ply-4 -20
75- Ply-1
0 75 - Ply-2 0 -300
0 50 100 150 0 50 100 150

Distanse from crack tip, mm Distanse from crack tip, mm Distanse from crack tip, mm

Fig. 4. Hoop stress versus the distance of crack tip with different layers: (a) [0] 8s, (b) [90]8s and (c) [0/90]4s
128 Amr A. Abd-Elhady et al. / Procedia Structural Integrity 5 (2017) 123–130
6 Amr A. Abd-Elhady et al. / Structural Integrity Procedia 00 (2017) 000–000

3.4 Effect of composite repair on the progressive crack path

The effect of composite repair on crack growth and path of a stationary crack is shown in Fig. 5. The picture in
each case has been taken after the crack path reached its steady state, i.e., at internal pressure equals Pc. The steady
state path of the growing crack is parallel to the pipe axis regardless of the inclination angle of the stationary crack.
The composite repair has no effect on the crack path, as shown in Fig.5. The value of internal pressure of the pipe at
stationary crack initiation, , Pi, is shown in Fig. 5. It can be seen that the pipe with composite repair has a higher
internal pressure value to initiate the stationary crack compared to the pipe without composite repair. Furthermore, the
value of crack initiation internal pressure decreased with an increase in the value of crack angle. This means that, the
most dangerous crack in the pipe subjected to internal pressure is the longitudinal crack.

 With repair Without repair

0o

Pi = 0.318262 MPa Pc = 0.31827 MPa Pi = 0.262329 MPa Pc = 0.26233 MPa

15o

Pi = 0.025031 MPa Pc = 0.02829 MPa Pi = 0.0197368 MPa Pc = 0.02489 MPa

45o

Pi = 0.0224373 MPa Pc = 0.28408 MPa Pi = 0.0163865 MPa Pc = 0.25532 MPa

75o

Pi = 0.021556 MPa Pc = 0.029311 MPa Pi = 0.0145091 MPa Pc = 0.025474 MPa

90o

Pi = 0.0206512 MPa Pc = 0.027013 MPa Pi = 0.0142894 MPa Pc = 0.023123 MPa

Fig. 5 The progressive crack path from inclined stationary crack in steel pipe based on XFEM
 Amr A. Abd-Elhady et al. / Procedia Structural Integrity 5 (2017) 123–130 129
Amr A. Abd-Elhady et al / Structural Integrity Procedia 00 (2017) 000–000 7

3.5 Effect of composite repair on the value of J-integral of stationary crack in steel pipe

As is already known, J-integral is a logical crack driving force in either linear elastic fracture mechanics or elastic-
plastic fracture mechanics. The J-integral concept examines the stress-strain conditions along an arbitrary contour
away from the crack tip. The crack will grow theoretically when the potential energy available for crack extension
reaches a critical value defined by J-integral. Therefore, decreasing J-integral in cracked pipe by the use of an
adhesively bonded composite repair patch increases the life of this pipe. The effect of composite repair patch on the
normalized value of J-integral (J-integral in pipe with composite repair patch/J-integral without composite repair
patch) of stationary crack in steel pipe with different  and different fiber orientation ([0o]8s uniaxial ply
circumferentially, [0o/90o]4s Cross ply, and [90o]8s uniaxial ply longitudinally) is illustrated in Fig. 6. Fig.6.a shows the
results of crack length equaling 35 mm, while Fig.5.b shows the results for crack length equaling 75 mm. Generally,
the efficiency of composite repair patch for reducing J-integral increased with an increase in the crack length for the
same patch dimensions and location. This may be attributed to the increase of the surface of the crack subject to closure
stress.

The highest reduction in normalized J-integral was found for stationary crack with  = 30o regardless of the fiber
orientation, and is more pronounced at the longer crack length. This may be attributed to the value of mode of mixity
(KII/KI) in each case. Recall Fig. 4, the mode of mixity of  = 30o is equal to 1.2 and 0.7 for crack length = 35 and 75
mm, respectively. In the case of  = 60o, the mode of mixity is equal to 0.5 and 0.4 for crack length = 35 and 75 mm,
respectively. It is clear that, the mode of mixity decreased with an increase in the crack length for  = 30o and 60o.The
highest values of KII, for crack length = 35 and 57 mm, were found for stationary crack with  = 30o, while the
corresponding values of KII for  = 90o were 0, i.e., pure mode I. Furthermore, the ratio of KI in the case of  = 30o to
that in the case of  = 90o is about 0.7 and 0.9 for the crack length = 35 and 75 mm, respectively. This means that, this
ratio increased with increasing crack length. From the previous observations, it can be concluded that, the crack closure
produced by adhesively bonded composite repair patch is more pronounced for larger crack length and high mode of
mixity for the same patch dimensions and location.

0.6 0.6
(b) a = 75 mm
Normalized J-Integral

(a) a = 35 mm
Normalized J-Integral

0.5 0.5

0.4 0.4

0.3 [0]8s 0.3 [0]8s

[0/90]4s [0/90]4s
0.2 0.2
[90]8s [90]8s
0.1 0.1

0 0
30 60 90 30 60 90

Inclined crack angle,  Inclined crack angle, 

Fig. 6. The effect of composite repair ([0o]8s uniaxial ply (circumferentially), [0o/90o]4s Cross ply and [90o]8s uniaxial ply (longitudinally),) on the
normalized value of J-integral of stationary crack in steel pipe under internal pressure.

For crack inclination angle = 30o, i.e., high mode of mixity, there is a marginal effect of fiber orientation regardless
of the crack length. In the other two cases, i.e., crack inclination angle = 60o and 90o, the effect of fiber orientation
increased, but it is not that pronounced. The reduction in J-integral is not highly affected by fiber orientation due to
the following two reasons. First, the ratio of the highest value of modulus of elasticity in composite laminates (E11) to
the lowest one E22, E11/ E22, is small, about 3.6. Second, the ratio of E11 to the modulus of the steel pipe material (E),
E11/ E equals 0.27. Therefore, it is recommended to use the high modulus carbon fiber reinforced epoxy for repairing
such cracked steel pipe, in order to increase the repair efficiency in the elastic range.
130 Amr A. Abd-Elhady et al. / Procedia Structural Integrity 5 (2017) 123–130
8 Amr A. Abd-Elhady et al. / Structural Integrity Procedia 00 (2017) 000–000

4. Conclusions

The results of the present numerical work support the following conclusions:
1- Whatever the inclination angle of the stationary crack in pipe under internal pressure, the crack will convert its
direction to grow under pure mode I, i.e., parallel to pipe axis.
2- The pipe with composite repair has a higher crack initiation pressure than that of pipe without composite repair.
3- The crack path is not affected by the presence of composite repair patch.
4- The composite repair reduces the value of J-integral of stationary crack in steel pipe and subsequently increases
the life of the pipe.
5- The crack closure produced by adhesively bonded composite repair patch is more pronounced for larger crack
length and high mode of mixity, for the same patch dimensions and location.

Acknowledgements

This work was funded by the Deanship of Scientific Research (DSR) at Jazan University, KSA. Project: DSR #
JUP7/069/2017.

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